Liquid Sample Package Device

ABSTRACT

A liquid sample packaging device includes a paperboard envelope blank assembled to form a hermetically sealed leakproof containment pocket that, in combination with proper alignment of a liquid containing packette enclosed inside, will prevent leakage in the event the enclosed liquid containing packette fails during mail processing. The device may include coupons printed on the envelope blank and separable by perforations, and may be printed on both sides.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No.14/953,013, filed Nov. 26, 2015, now RE46,998 E, granted Aug. 21, 2018,which is a Reissue application of U.S. application Ser. No. 13/109,536,filed May 17, 2011, claiming the benefit of U.S. Provisional ApplicationSer. No. 61/345,197 filed May 17, 2010 and which issued as U.S. Pat. No.8,590,770, granted Nov. 26, 2013, and is a continuation-in-part of U.S.application Ser. No. 14/923,408, filed Oct. 26, 2015, which claims thebenefit of U.S. Provisional Application Ser. No. 62/067,998, filed Oct.24, 2014, all of which are incorporated herein by reference.

TECHNICAL FIELD

This disclosure generally relates to a liquid sample packaging deviceand, more particularly, to a letter size bulk mailing packaging devicewith improved features to contain and display liquid samples.

BACKGROUND

Many manufacturers of cosmetics, toiletries, beauty and skincareproducts, etc. commonly promote their products by distributing freesamples to current or potential consumers with the goal of buildingand/or maintaining customer loyalty for the products or product lines.One method of distributing such samples has been to give them topotential customers in a store in which the product is specificallysold. A more effective method has been mailing packages containingsample packettes to a targeted audience through the U.S. Postal Service(USPS).

Mail packages distributed through the USPS have been mailed either undera non-discounted rate classification or under a more economical bulkrate classification. To qualify for classification under the bulk mailrate, each mail package must comply with certain guidelines set by theUSPS, including size requirements based on length, height and thickness,and further requiring the length/height aspect ratio be within a certainrange. The requirements for obtaining the bulk mail rate are documentedin the USPS Domestic Mailing Manual (DMM).

When the sample packette contains a fluid and/or volatile compositionsuch as a liquid, USPS guidelines also require that the mailing packagemust be capable of being processed by bulk mail sorting equipmentthrough delivery without leakage of any liquid. As used herein, “liquid”refers to any liquid, creme, lotion, color cosmetic, gel, paste, orother fluid product, and any aromatic, fragrance or other volatileproduct in any form, such as sachet, that could potentially leak orevaporate from the sample packette containing the liquid if the samplepackette, which is the primary liquid retention device, fails at anypoint during bulk mail processing through delivery to the recipient. Aliquid containing sample packette shall be referred to subsequently as a“sample liquid packette.”

Not later than May 2008 the USPS DMM requirements could be met bypackaging, referred to as “cartons,” that were relatively thick (up to ¾inch) and sturdy but which still qualified for a low bulk mail rate.Some bulk mailers utilized plastic to wrap liquid sample bulk mailingpackages in order to meet liquid leakage prevention requirements. TheUSPS bulk mailing package requirements were changed as the USPS changedequipment. The new requirements were included with modifications to theDMM as the DMM was transformed into a series of documents dated May2008, the entire series of DMM documents incorporated herein byreference in their entirety. In particular, section 201 for “PhysicalStandards” with its sub-subsection 1.1.1 for “Dimensional Standards forLetters” within subsection 1.1 for “Physical Standards for MachinableLetters;” its subsection 3.0 for “Physical Standards for Machinable andAutomation Letters and Cards” with all its sub-subsections; and section601 for “Mailability” with all its subsections are incorporated hereinby reference in their entirety.

The net result of changes to the DMM in May 2008 was that cartons orplastic wrapping used for liquid sample bulk mailing packages were, at aminimum, subject to a substantially higher “large envelope” or “Not-FlatMachinable” bulk mail rate. A lower USPS machine-readable mailing rateapplicable to letter size bulk mail is not available for plastic wrappedmailings and is available only for items up to ¼ inch thick that meetother size and flexibility requirements. Cartons are both thicker than ¼inch and relatively rigid in construction, thus unable to meet the newrequirements. Due to the increased costs of mailing through the USPS,manufacturers of liquid products subsequently sought alternative methodsto place product samples, including distribution of samples in stores orother location frequented by likely customers, such as malls, conventioncenters, or cruise ships. Distribution through these methods are not aseffective in reaching potential customers likely to purchase a productafter trying a sample as previously used targeted mailings, which werebased on customer information available to manufacturers and/or theirmarketers.

Accordingly, there is a need for a liquid sample packaging device thatcan serve as a bulk mailing packaging device capable of meeting the USPSrequirements for obtaining the bulk mail rate for automated/machinableletters. There is also a need for a cost effective liquid sample bulkmailing package assembly method. There is also a need for a liquidsample bulk mailing package that can, without plastic wrapping aroundthe external package surface, prevent leakage or evaporation outside thepackage in the event of failure of the sample liquid packette from theinitial deposit of the package with the USPS through the mail sortingand delivery process to the ultimate recipient. Such a liquid samplepackaging device could also be used for distribution to potentialcustomers means other than through the U.S. postal system.

SUMMARY

A liquid sample bulk mailing packaging device, and method for assemblingthe device, is provided that enables mailing liquid samples under the USPostal Service requirements for machinable and automation letters.Paperboard panels hermetically seal a liquid sample packette such thatmoisture will not leak from the hermetically sealed section of thepackaging device. In one embodiment, paperboard having sufficientabsorption capabilities to absorb liquid in sample packettes is coatedon the surface opposite where the packettes are placed such thatmoisture will not leak from an assembled package in the event of failureof the packettes during the mailing process and instead will be absorbedby the paperboard, in other embodiments the paperboard is coated and notabsorptive while the hermetic seal is sufficient to prevent leakage fromthe assembled package in the event of failure of the packettes.

According to one disclosed embodiment, an envelope blank is providedwith paperboard having a first side coated with a semi-permeable coatingto form a printable surface, print media being placed on at least aportion of the surface and a moisture resistant coating placed on theprint media and semi permeable coating, with a perforated couponincluded in the envelope blank. The opposite, second, side of thepaperboard is uncoated such that it can absorb moisture. A picture framecut-out is made in a first panel extending from the top edge with anon-permeable window glued to the second side. A second panel extendsfrom the first panel towards the bottom edge and has a liquid packettemounting area on its second side. In another embodiment, the oppositesecond side of the paperboard may also have a semi-permeable coating toform a printable surface, print media being placed on at least a portionof the surface and a moisture resistant coating placed on the printmedia and semi permeable coating.

According to another embodiment, a liquid sample bulk mailing packagingdevice uses an envelope blank made from paperboard having asemi-permeable coated first side that forms a printable surface, printmedia placed on at least a portion of the printable surface, and amoisture resistant coating overlying the print media and semi-permeablecoating. The paperboard's second side may be uncoated, providing amoisture absorbing surface, or may be coated to enable print media to beapplied to the second side. The envelope blank has a first panelextending from a top edge and a second panel adjacent the first panel. Asample liquid packette has a cover film laminated to a backing film andcontains a volume of liquid. The sample liquid packette has a burststrength and provides the primary seal for containing the liquid duringmailing. The sample liquid packette is glued to a packette mounting areaon the second side of the second panel by a fugitive glue. A permanentglue is applied to the perimeter of the packette mounting area from afold line between the first panel and the second panel, such that thesample liquid packette is encircled by the fold line and the permanentglue. The first panel is folded to, and glued to, the second panelpackette mounting area. Once glued, a hermetic seal is formed around thesample liquid packette, providing a secondary seal to prevent anyleakage of liquid from the sample liquid packette from escaping theliquid sample bulk mailing packaging device. The liquid sample bulkmailing packaging device is not greater than ¼ inch thick and is withinthe United States Postal Service requirements for automation letters.The liquid sample bulk mailing package device may include a perforatedcoupon or a separately attached coupon.

According to a further embodiment, a method of assembling a liquidsample bulk mailing packaging device involves providing an envelopeblank formed from at least one side clay coated paperboard, andpreprinted with print media on the at least one clay coated side toprovide attractive and informational graphic presentations in a fourpanel area. A moisture resistant coating overlies the print media, andthe first panel includes a non-permeable window glued to its secondside. The envelope blank has a top, bottom, and first and second lateraledges. A first tab is cut along the first lateral edge in the firstpanel near a fold line between the first and second panels, and a secondtab is cut opposite the first tab along the second lateral edge. Astring is glued to the second side extending from the first tab to thesecond tab. A fugitive glue is applied to the second side of the secondpanel for placement of a sample liquid packette. A line of permanentglue is applied to the second side of the second panel around the sampleliquid packette from a first fold line between the first and secondpanels such that when the first panel is folded and glued to the secondpanel a hermetic seal is formed around the sample liquid packette.Permanent glue is also applied around the periphery of the second sideof the third panel and the fourth panel is folded and glued to it. Afugitive glue is then applied to the first side of the first panel,which is then folded towards the fourth panel so the first and fourthpanels printed sides are glued together with fugitive glue, enablingeasy opening by a mailing recipient. Addressee information is thenprinted in an address area on the first side of the second panel. Thismethod enables an efficient, cost-effective assembly of letter sizeenvelopes with sample liquid packettes enclosed for mailing at the lowmachinable, automation letter rate. In another embodiment the oppositesecond side may also be clay coated with print media provided in atleast one of the four panel areas, and may include a perforated couponin one of the third and fourth panels. In another embodiment, the bulkmailing packaging device consists of three panels, and may have aperforated coupon in either the third panel, extending from the windowedge, or both.

Other features, benefits and advantages of the disclosed embodimentswill become apparent from the following description of embodiments, whenviewed in accordance with the attached drawings and appended claims.

BRIEF DESCRIPTION OF THE ILLUSTRATIONS

FIG. 1 is an illustration of a plan view of a first side of a die-cutblank for a liquid sample bulk mailing packaging device.

FIG. 1A is an enlarged schematic illustration of a partialcross-sectional view of the diecut blank taken along line 1A-1A of FIG.1.

FIG. 2 is an illustration of a plan view of the second side of a die-cutblank of FIG. 1 partway through the assembly process.

FIG. 3 is an illustration of a plan view of the diecut blank of FIG. 1after attachment of the sample liquid packette and partial assembly intoa liquid sample bulk mailing packaging device.

FIG. 4 is an illustration of an assembled liquid sample bulk mailingpackaging device.

FIG. 5 is an illustration of cross-sectional view of the assembled bulkmailing packaging device taken along lines 5-5 in FIG. 4.

FIG. 6 is an illustration of a plan view of a first side of a diecutblank for a liquid sample bulk mailing packaging device.

FIG. 6A is an illustration of a plan view of a first side of a diecutblank for another embodiment of a liquid sample bulk mailing packagingdevice using three panels.

FIG. 6B is an enlarged schematic illustration of a partialcross-sectional view of the diecut blank taken along line 6B-6B of FIG.6 and FIG. 6A.

FIG. 7 is an illustration of a plan view of the second side of a die-cutblank of FIG. 6 partway through the assembly process.

FIG. 7A is an illustration of a plan view of the second side of adie-cut blank of FIG. 6A partway through the assembly process.

FIG. 8 is an illustration of a plan view of the diecut blank of FIG. 6after attachment of the sample liquid packette and partial assembly intoa liquid sample bulk mailing packaging device.

FIG. 8A is an illustration of a plan view of the diecut blank of FIG. 6Aafter attachment of the sample liquid packette and partial assembly intoa liquid sample bulk mailing packaging device.

FIG. 9 is an illustration of an assembled liquid sample bulk mailingpackaging device.

FIG. 10 is an illustration of cross-sectional view of the assembled bulkmailing packaging device of FIG. 6 taken along lines 10-10 in FIG. 9.

FIG. 10A is an illustration of cross-sectional view of the assembledbulk mailing packaging device of FIG. 6A taken along lines 10-10 in FIG.9.

DETAILED DESCRIPTION

FIG. 1 shows an embodiment of a diecut envelope blank 10 for use informing a liquid sample bulk mailing packaging device, illustrating afront, printed side 11 of the envelope blank 10. As shown in more detailin an enlarged schematic illustration of FIG. 1A, the envelope blank 10is made from a paperboard 12 having a first side 14 with asemi-permeable coating 18, such as a clay coating, forming a printablesurface 20 and on which print media 22 is placed on at least a portion.A moisture resistant coating 24, such as an aqueous coating, overliesthe print media 22 and semi permeable coating 18, while a second side 16of the paperboard 12 is uncoated on at least a portion, providing anabsorbable surface area. While exaggerated for illustration purposes,the raw surfaces of paperboard 12 are not smooth, thus, thesemi-permeable coating 18 enhances the ability to apply attractive printmedia 22.

As further illustrated in both FIG. 1 and FIG. 2, which depicts the backside 13 of the envelope blank 10 partway through the assembly process inmaking a liquid sample bulk mailing device, the envelope blank 10 has atop edge 60, a bottom edge 62, a first lateral edge 64, and an oppositesecond lateral edge 66. In the embodiment illustrated, a four panelenvelope blank 10 is shown. A first panel 28 extends from the top edge60 to a first fold line 44, a second panel 38 extends from the firstfold line 44 to a third fold line 48, a third panel 40 extends from thethird fold line 48 to a second fold line 46, and a fourth panel 42extends from the second fold line 46 to the bottom edge 62.

The first panel 28 has a picture frame cutout 30 having print media onthe printed side 11 providing an attractive display around anon-permeable window 32, such as a plastic or a metallized plastic film,adhered and sealed to the second side 16 of the paperboard 12,preferably by a permanent glue 34 that has been applied in a continuousline encircling the periphery 36 of the picture frame cutout 30. As usedherein, a permanent glue is any adhesive that will bind with at leastone of the contacting surfaces in a substantially permanent way suchthat removal of one surface from the adhered surface will pull a portionof the adhered surface material from its surface. In one embodiment, afirst tab 68 is cut along the first lateral edge 64 in the first panel28 proximate the first fold line 44 and a second tab 70 is cut oppositethe first tab 68 along the second lateral edge 66 with a tear string 71adhered by a permanent glue to the second side 16 extending from thefirst tab 68 to the second tab 70. In another embodiment, the second tab70 could be omitted, and the tear string 71 would simply extend towardsthe second lateral edge 66. The tear string 71 is made from a materialthat when adhered to the paperboard 12 has a greater tensile strengththan the paperboard material itself. In one embodiment, the tear string71 is a string, such as a flat polyester ribbon about ⅛ inch wide, orany other string material available having sufficient tensile strength.

The second panel 38 includes on the printed side 11 an attractive andinformational graphic presentation, a blank address area 74, a marking75 meeting the USPS requirements indicating that a liquid sample isenclosed, and a bulk mailing permit 77. The back side 13 of the secondpanel 38 includes an uncoated portion of paperboard 12 providing apackette mounting area 26. A fugitive glue 72 is applied to the packettemounting area 26 by which a sample liquid packette 50 can be adhered tothe second panel. As used herein, a fugitive glue is an adherentsubstance substantially holding two surfaces together but capable ofreleasing one surface from the other substantially without tearingmaterial from a surface, as is known in the art. A line of permanentglue 37 is applied from the first fold line substantially around theperiphery of the area for holding the sample liquid packette 50, suchthat when the first panel is glued to the second panel a substantiallyhermetic seal is formed around the liquid packette 50. In the embodimentillustrated, a line of permanent glue 37 extends from proximate thefirst fold line 44 at a point inward of the first tab 68 extendingsubstantially diagonally outward, towards the first lateral edge 64, andthen extending generally parallel to the first lateral edge towards thethird fold line 48, then extending generally parallel to the third foldline 48 towards the second lateral edge 66, then extending generallyparallel to the second lateral edge 66 towards the first fold line 44,then extending substantially diagonally inward to a point inward of thesecond tab 70.

The printed side 11 of the third and fourth panels 40, 42 may includeattractive and informational graphic presentations, and the third panelmay include an information block for coupon placement 80. The back side13 of the third panel 40 includes permanent glue 41 provided around theperiphery of the panel, proximate to and parallel with the second foldline 48, the third fold line 48, the first lateral edge 64, and a secondlateral edge 66.

FIG. 3 shows a partially assembled liquid sample bulk mailing packagingdevice using the envelope blank 10 after adhering the sample liquidpackette 50 to the packette mounting area 26 of the second panel 38,folding the back side 13 of the first panel 28 towards the second panel38 along the first fold line 44 and gluing to it to the second panel,and folding the back side of the fourth panel 42 towards the third panel40 along the second fold line 46, with the view rotated 180° from theviews of FIG. 1 and FIG. 2 for clarity. A fugitive glue 72 is applied tospots on the first panel 28 proximate the first lateral edge 64, thefirst fold 45, and the second lateral edge 66, for adhering the firstpanel 28 to the fourth panel 42 on final assembly, and to an informationblock 80 for coupon placement. A coupon 78 including a coupon barcode 82uniquely identifying the coupon is releasably adhered to the informationblock 80 by the fugitive glue 72. The sample liquid packette 50 issubstantially covered by the nonpermeable window 32 and substantiallyhermetically sealed between the first panel 28 and the second panel 38by the first fold line 44, and the line of permanent glue 37 surroundingthe sample liquid packette 50, such that a substantially leakproofcontainment pocket 73 is formed around the sample liquid packette 50.The sample liquid packette 50 includes a cover film laminated to abacking film and contains a volume of liquid, the sample liquid packettehaving a burst strength and providing a primary sealing means forcontaining the liquid during mailing. It has experimentally been foundthat a burst strength less than 1000 pounds force applied to a platenover the surface of the packette is insufficient to meet the demands ofthe USPS letter size bulk mailing equipment. It has also beenexperimentally found that a burst strength of about 1500 pounds forceapplied to a platen over the area of the packette, also found to be aminimum of 22 psi, can meet the USPS requirements. In one embodiment,the sample liquid packette 50 includes three packette portions separatedvertically as shown in the figures. Alignment of multiple packetteportions vertically enables a manufacturer to provide samples of relatedproducts, such as a shampoo, a conditioner, and a cream. The tear string71 shown in hidden lines provides an important convenience to consumersto allow them easy opening by simply pulling the tear string to tear thepaperboard 12 from either end, the first tab 68 or the second tab 70, sothat the liquid sample packette 50 can be removed from the sealedpackage. There are no perforations through the paperboard in between thefirst tab 68 and the second tab 70 so that the integrity of the moistureresistant coating 24 is intact over the hermetically sealed leakproofcontainment pocket 73 during the mailing process through delivery.

FIG. 4 shows a completely assembled liquid sample bulk mailing packagingdevice 51 as an envelope 52 formed from the envelope blank 10 after thecoupon 78 is adhered to the information block 80 and the first panel 28is folded along the third fold line 48 and glued to the fourth panel 42.The envelope 52 has a length 54 between 5 and 11.5 inches, a height 56between 3.5 and 6.125 inches, and a thickness 58 as shown in the crosssection of FIG. 5 no greater than 0.25 inches. An aspect ratio of thelength divided by the height is between 1.3 and 2.5. In one embodiment,the length 54 is about 9 inches, the height 56 is about 6 inches, andthe thickness 58 is no more than 0.25 inches. The liquid sample bulkmailing packaging device 51 has a weight no greater than 3.5 ounces, andhas a flexibility sufficient to bend around an 11 inch diameter drumwhen subjected to a transport belt tension of 40 pounds. A targetedaddress 76 and associated address barcode 84 are applied to the addressarea 74 after successful completion of the assembly process includingeach of the first, second, and third folds to ensure the targetedaddress 76 can be linked to the coupon barcode 82 by a computer andstored in a computer database. Any envelope 52 that fails to completethe assembly process successfully can be discarded while ensuringtargeted addresses with associated barcoded coupons are successfullyincluded in the automated bulk mailing, thus enabling the manufacturerto efficiently mail samples and track coupon redemption directly to theconsumer.

The liquid sample bulk mailing packaging device 51 shown in crosssection in FIG. 5 illustrates the first panel 28 with its nonpermeablewindow 32 and second panel 38 forming a substantially leakproofcontainment pocket 73 in which sample liquid packette 50 is attached tothe liquid packette mounting area 26. The sample liquid packette 50 hasa cover film 86 laminated to a backing film 88 and holds a volume ofliquid 90. The sample liquid packette 50 has a burst strength more than1000 PSI and preferably at least about 1500 PSI as measured by ASTMtesting method F-1140. In one embodiment, the paperboard 12 is solidbleached sulfate (SBS) clay coated, one side only, 0.012 inch thick.Print media is applied to the clay coated side, with an aqueous coatingthen applied to form the printed side 11. In the event the primaryliquid retention from the sample liquid packette 50 fails, the liquidmay leak into the substantially leakproof containment pocket 73 and maybe absorbed by the paperboard 12. In order to absorb the liquid, thepaperboard should have sufficient absorption capability to absorb thequantity of liquid contained within the sample liquid packette 50 withthe semi-permeable coating 18 and the moisture resistant coating 24preventing transmission of the liquid 90 by leakage or evaporationthrough the paperboard 12 from the deposit time of the liquid samplebulk mailing packaging device 51 with the USPS through the mail sortingand delivery process to the ultimate recipient. Thus, it is not requiredthat a moisture resistant coating 24 have indefinite moisture resistantcapabilities, but should be durable enough to retain the liquid for atleast about two weeks. One advantage of using the system is that itmeets the USPS requirements for machinable and automation letters,whereas plastic wrapped envelopes do not meet this requirement.

Absorption capabilities of paperboard 12 is measured by the Cobb valuein grams per square meter. A minimum Cobb value relative to the moisturecontent of the liquid volume contained in the sample liquid packette 50will be apparent to those skilled in the art based on the teachingsherein. Portions of the back side of the envelope blank 13 includingwithin the liquid packette mounting area 26 may have printing or inkapplied so long as a Cobb value sufficient to absorb the moisturecontent of the sample liquid packette 50 is retained, as such is notapplication of a coating that would inhibit absorption beyond thatnecessary to meet the USPS requirements. A Cobb value of at least about50 g per square meter has been found sufficient in combination with aprinted surface having a clay coating and aqueous moisture resistantcoating, as the combined effect is to absorb moisture while retainingthe liquid for the time necessary for the mailing process to becomplete.

FIG. 6 through FIG. 10A show embodiments that may have a clay coatedsecond side 116 enabling high-quality print media to further enhance aliquid sample bulk mailing package device, with reference numeralsdepicting features as previously discussed with reference to thedescriptions of FIG. 1 through FIG. 5.

FIG. 6 shows an embodiment of a diecut envelope blank 10 for use informing a liquid sample bulk mailing packaging device, illustrating afront, printed side of the envelope blank 10, and including an optionalcoupon 178 that is detachable by means of perforations 179. While noperforations are permitted in panel portions surrounding a liquidsample, other panels or portions of a panel not in contact with theliquid sample may have perforations thus enabling a coupon to be printeddirectly on envelope blank 10. FIG. 6 shows a four panel embodiment witha coupon 178 in the fourth panel, while FIG. 6A shows a three panelembodiment with the picture frame cutout modified to include a coupon178 detachable by perforations 179. One or both such coupons may beincluded in the envelope blank 10.

As shown in more detail in an enlarged schematic illustration of FIG. 6Bthe envelope blank 10 is made from a paperboard 12 having a first side14 including a coating and printing configuration as previouslydiscussed with respect to FIG. 1A but further having the analogouscoating and printing configuration on second side 116, including a semipermeable coating 118, such as a clay coating, forming a printablesurface 120 and on which print media 122 is placed on at least aportion. A moisture resistant coating 124, such as an aqueous coating,may overlie the print media 122 and semi permeable coating 118. Whileexaggerated for illustration purposes, the raw surfaces of thepaperboard 12 are not smooth, thus the semi permeable coating 118enhances the ability to apply attractive print media 122.

As further illustrated in FIGS. 6, 6A and FIG. 7, which depicts thebackside 113 of the envelope blank partway through the assembly processin making a liquid sample bulk mailing device, similar to the backside13 as previously shown in FIG. 2, print media is placed on second panel38, third panel 40, and fourth panel 42, which can include a couponbarcode 182 on the backside of coupon 178. Fugitive glue 72 can beapplied to one of the third panel 40 and/or fourth panel 42 to holdthese panels together during the assembly process while allowing therecipient of the liquid sample bulk mailing package device to easilyopen the device to these panels and see an attractive and informationalgraphic presentation in these additional panel areas, which areunavailable for viewing if a permanent glue is used. A dual liquidsample packette 150 is shown having to portions or samples with aperforation 147 enabling the recipient to split the individual packettesfor use individually. Packette 150 includes an easy opening feature,such as notches 149, to enable easy opening by the recipient. Theopening feature on the packette is the weakest point for the packetteand orientation with respect to forces applied in USPS sorting equipmentis critical. While vertical orientation such as shown in FIG. 2 and FIG.3 in combination with the necessary packette strength enabled successfulprocessing when tested in USPS equipment, the same packettes would failif the opening feature 149 was in a horizontal orientation and locatedat the aft end with respect to the direction of travel 200 (as shown inFIG. 9) through the USPS processing equipment. Tests confirmed that apackette 150 with the opening feature 149 located at the forward end(with respect to the direction of travel 200) fared better in tests, theresult of rollers pushing the enclosed liquid aft as a device movesthrough the equipment and increasing the internal pressure such that aweak point such as the opening feature would fail. It has also beendetermined that the packette should not be too close to the leadingedge. Current USPS equipment process bulk mail at speeds up to 300pieces per minute, with a very rapid initial acceleration to theprocessing speed. This acceleration is enabled by rollers that grab thedevice imparting significant initial force to bring the device from zeroto the operating speed in ⅕ of a second. It has been determined thatthere is a critical leading edge portion that must not include thesample liquid packette 50 so that the initial force enabling the highacceleration can be applied only to the paperboard 12. FIG. 7 similarlyillustrates the backside 113 of a three panel envelope blank 10 withprinting shown on the perforated coupon 178 of FIG. 6A.

Proper placement of packette 50 is illustrated in FIG. 8, FIG. 8A andFIG. 9. As illustrated in FIG. 8 and FIG. 8A, packette 50 has outline105 shown as a hidden line with a packette leading edge 106 located adistance 114 from a device leading edge 110, distance 114 being greaterthan a critical leading edge clearance distance 112. Likewise, packette50 must be located a minimum distance 128 from all edges to avoid damagefrom the mail processing equipment, such as shown for the distance 126to the bottom edge 127 of packette 50.

Paperboard 12 coated on both sides enables additional panels to accepthigh quality printing, as compared to low quality printing that could beaccomplished without any coating. While a coating on the backside of thepaperboard will inhibit absorption of a liquid in the event of a failureof the primary liquid containment apparatus, the hermetic seal of thefirst and second panels by a permanent glue and non-permeable window hasbeen determined sufficient to prevent leakage and damage to current USPSequipment. High quality printing on both sides enables betterdemonstration of products and services to prospective customers, andgreatly enhances the ability to provide visual material that will betterget the attention of the recipient of a liquid sample bulk mailingpackage device. The entire piece has a more upscale and high classfinished look.

Further, experimentation has shown that the opening end of the packettescan be placed both in a vertical position and a horizontal position withthe opening end of the packette as the lead edge as it travels throughthe USPS Automated Letter Sorting Equipment. Advantages are that artworkcan be positioned in both a vertical and horizontal direction in themailer which will give more options for attention gettinggraphics—including high quality graphics behind the packettes providingartwork and information when the packette is removed from the device.The packette will maintain its burst integrity by not allowing itsopening feature to be the trailing edge going through the sortingequipment. It has been determined that a minimum clear distance from theleading edge for the packetter is at least 1″ and from all other edgesat least ½″. Maintaining this clearance from edges will protect thepackette from breaking and/or being damaged when travelling through theUSPS mail delivery system including both automated equipment with rollerbars and wheels and guide bars, and hand sorting/delivery.

While specific embodiments of the present invention have been described,it will be apparent to those skilled in the art that variousmodifications thereto can be made without departing from the spirit andscope of the invention. Accordingly, the foregoing description ofembodiments of the invention are provided for the purpose ofillustration only and not for the purpose of limitation, the inventionbeing defined by the claims.

What is claimed is:
 1. An envelope blank comprising: paperboard having afirst side, a second opposite side, a top edge, a bottom edge, a firstlateral edge, and an opposite second lateral edge; the paperboard coatedon the first side with a semi-permeable coating to form a printablesurface; print media placed on at least a portion of the printablesurface; a moisture resistant coating overlying the print media andsemi-permeable coating; a first panel extending from the top edge havinga picture frame cutout with a non-permeable window adhered to the secondside; and a second panel extending from the first panel with the secondside having a liquid packette mounting area, with at least a portion ofthe paperboard in the liquid packette mounting area coated with asemi-permeable coating to form a printable surface and print mediaplaced on at least a portion of the printable surface.
 2. The envelopeblank of claim 1 wherein the non-permeable window is formed from thegroup consisting of plastic and metalized plastic films.
 3. The envelopeblank of claim 2 wherein the non-permeable window is adhered to thesecond side by a permanent glue encircling the periphery of the pictureframe cutout.
 4. The envelope blank of claim 1 wherein the envelopeblank is die-cut in a substantially rectangular shape for folding intoan envelope having a length, a height, and a thickness when enclosing asample liquid packette, the envelope blank further comprising: a thirdpanel extending from the second panel to the bottom edge; a first foldline between the first panel and the second panel; a second fold linebetween the second panel and the third panel; a first tab cut along thefirst lateral edge in the first panel proximate the first fold line; asecond tab opposite the first tab and cut along the second lateral edgein the first panel proximate the first fold line; a tear string having atensile strength greater than the paperboard tensile strength, the tearstring adhered to the second side of the first panel extending from thefirst tab to the second tab.
 5. A liquid sample packaging devicecomprising: the envelope blank of claim 4; a sample liquid packettecomprising a cover film laminated to a backing film and containing avolume of sample liquid, the sample liquid packette having a burststrength and providing a primary sealing means for containing the sampleliquid, the sample liquid packette adhered to the packette mounting areaon the second side of the second panel by a fugitive glue; and apermanent glue applied to the perimeter of the packette mounting areafrom the first fold line, such that the sample liquid packette isencircled by the fold line and the permanent glue, the first panelfolded to and glued to the second panel packette mounting area forming ahermetic seal around the sample liquid packette, the hermetic sealproviding a secondary sealing means to prevent leakage of liquid fromthe sample liquid packette from the liquid sample packaging device. 6.The envelope blank of claim 1 wherein the envelope blank is die-cut in asubstantially rectangular shape for folding into an envelope having alength, a height, and a thickness when enclosing a sample liquidpackette, the envelope blank further comprising: a third panel extendingfrom the second panel towards the bottom edge; a fourth panel extendingfrom the third panel to the bottom edge; a first fold line between thefirst panel and the second panel; a second fold line between the thirdpanel and the fourth panel; a third fold line between the second paneland the third panel; a first tab cut along the first lateral edge in thefirst panel proximate the first fold line; a second tab opposite thefirst tab and cut along the second lateral edge in the first panelproximate the first fold line; and a tear string having a tensilestrength greater than the paperboard tensile strength, the tear stringadhered to the second side of the first panel extending from the firsttab to the second tab.
 7. A liquid sample packaging device comprising:the envelope blank of claim 6; a sample liquid packette comprising acover film laminated to a backing film and containing a volume of sampleliquid, the sample liquid packette having a burst strength and providinga primary sealing means for containing the sample liquid, the sampleliquid packette adhered to the packette mounting area on the second sideof the second panel by a fugitive glue; and a permanent glue applied tothe perimeter of the packette mounting area from the first fold line,such that the sample liquid packette is encircled by the fold line andthe permanent glue, the first panel folded to and glued to the secondpanel packette mounting area forming a hermetic seal around the sampleliquid packette, the hermetic seal providing a secondary sealing meansto prevent leakage of liquid from the sample liquid packette from theliquid sample packaging device.